Packing apparatus for an automated manufacturing system of lithium secondary battery

ABSTRACT

An packing apparatus for an automated manufacturing system of a secondary lithium battery is disclosed. The packing apparatus comprises: a frame; a base member which is installed at the frame, and is provided with a receiving rack for receiving a batch of separator both surfaces of which are laminated with positive electrode plates and negative electrode plates in a predetermined pattern; a stopper member installed at the frame to be linearly movable so as to selectively approach one end of the base member for preventing the separator being supplied to the base member from being separated from the receiving rack; a folder member installed at the frame to be linearly movable with respect to the receiving rack so that the folder can press the separator supplied to a receiving space formed by the receiving rack and the stopper member for predetermined duration, and fold the separator so that both side sections of the folded separator can have the shape of “Z”, and the positive electrode plates and the negative electrode plates can alternate with each other; and a cutting/taping member for moving the separator folded in the shape of “Z” to a predetermined area, cutting the separator at a non-electrode plate area to which no electrode plate is attached, and taping the folded and cut piece of separator.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a packing apparatus for an automatedmanufacturing system of a lithium secondary battery, and moreparticularly, to a packing apparatus for an automated manufacturingsystem of a lithium secondary battery capable of packing a crude cell,in which after both surfaces of a predetermined length of separatorwhich is supplied from a roll of separator in the form of film and isarranged to travel along a horizontal path are laminated with a batch ofpositive electrode plates and negative electrode plates and thelaminated separator is folded in a fold/fold fashion, a crude cell canbe manufactured in a continuous process line by cutting a laminatedpiece of separator from the roll of separator and taping the piece ofseparator.

2. Description of the Related Art

In general, as portable electronic products such as video cameras,portable phones, and portable PCs become lighter, or highly functional,various development and research have been focused on batteries used aspower sources of such portable electronic products. Such batteries canbe used continuously by recharging the batteries.

Among various batteries, usually, nickel cadmium batteries, nickelhydrogen batteries, nickel zinc batteries, lithium secondary batteriesand the like are used as power sources of electronic products, and, inparticular, lithium secondary batteries are generally used taking intoconsideration the use life and capacity thereof.

According to types of electrolyte, the lithium secondary batteries areclassified into lithium metal batteries and lithium ion batteries whichemploy liquid electrolyte, and lithium polymer batteries which employsolid polymer electrolyte. According to types of solid polymerelectrolyte, the lithium polymer batteries are classified intofull-solid type lithium polymer batteries in which organic electrolyticliquid is not included at all, and lithium ion polymer batteriesemploying gel type polymer electrolyte containing organic electrolyticliquid.

The lithium secondary battery is manufactured by stacking a plurality ofunit cells having a separator-electrode structure so as to meet arequired capacity, connecting the unit cells to each other in parallel,and packing the unit cells into a cylindrical or polyhedral can.

However, in a battery in which electrode plates are disposed accordingto a conventional method, there is a problem in which when the batteryis overcharged, a voltage of the battery rises drastically, and theenergy of the battery may be instantaneously discharged and theelectrolyte may evaporate or burn, and therefore the performance of thebattery and safety thereof deteriorate. In addition, there is anotherproblem in which the process of attaching electrode taps forelectrically connecting unit cells to each other is very complicated.

SUMMARY OF THE INVENTION

To solve the above-described problems, it is an objective of the presentinvention to provide a packing apparatus for an automated manufacturingsystem of a secondary battery having an improved structure capable ofautomating operations of folding a separator both surfaces of which arelaminated with positive electrode plates and negative electrode platesso that both side sections of the separator can have the shape of “Z”(fold/fold fashion), cutting the separator, taping the folded separator,unloading the packed separator, and the like in a continuous processline.

Accordingly, to achieve the above objectives, there is provided apacking apparatus for an automated manufacturing system of a secondarylithium battery comprising: a frame; a base member which is installed atthe frame, and is provided with a receiving rack for receiving a batchof separator both surfaces of which are laminated with positiveelectrode plates and negative electrode plates in a predeterminedpattern; a stopper member installed at the frame to be linearly movableso as to selectively approach one end of the base member for preventingthe separator being supplied to the base member from being separatedfrom the receiving rack; a folder member installed at the frame to belinearly movable with respect to the receiving rack so that the foldercan press the separator supplied to a receiving space formed by thereceiving rack and the stopper member for predetermined duration, andfold the separator so that both side sections of the folded separatorcan have the shape of “Z”, and the positive electrode plates and thenegative electrode plates can alternate with each other; and acutting/taping member for moving the separator folded in the shape of“Z” to a predetermined area, cutting the separator at a non-electrodeplate area to which no electrode plate is attached, and taping thefolded and cut piece of separator.

In the packing apparatus for an automated manufacturing system of asecondary lithium battery, the base member comprises: a guiding jawprojected from a base plate to guide the separator supplied thereto; anda pair of recessed portions recessed into both sides of the receivingrack.

In the packing apparatus for an automated manufacturing system of asecondary lithium battery, the base member further comprises a biasingmember installed at the frame for biasing the separator toward thestopper member so that the separator supplied to the receiving rack canbe easily folded in the shape of “Z”.

In the packing apparatus for an automated manufacturing system of asecondary lithium battery, it is preferable that the stopper member hasa stopper fork for blocking both sides of the base member, and islinearly moved by a stopper moving member.

In the packing apparatus for an automated manufacturing system of asecondary lithium battery, the folder member comprises a folder platemoved by a folder cylinder.

In the packing apparatus for an automated manufacturing system of asecondary lithium battery, the cutting/taping member comprises: a pairof clamp members for approaching both sides of the base member, clampingboth sides of a piece of separator folded in the shape of “Z”, andmoving the piece of separator horizontally to a taping position; acutting member installed at the frame to be movable for cutting theseparator at the leading end of the base member after the separator hasbeen moved by the clamp member; a tape supplying member installed at theframe to attach one end of tape to the piece of separator after a taperoller around which the tape is wound is moved along a tape travel path;clamp rotating members installed at the frame for rotating the clampmembers predetermined times so that the piece of separator can be tapedwhile the piece of separator to which one end of the tape is attached isrotated at both ends thereof; and a tape cutting member installed at thetape supplying member to be movable for cutting the loose end portion ofthe tape extended from the packed piece of separator which has beenrotated by the clamp rotating members and has been packed with the tape.

In the packing apparatus for an automated manufacturing system of asecondary lithium battery, the cutting/taping member further comprises aholder member installed at the frame to be raised and lowered so thatthe holder member can approach the tape supplying member and contact onesurface of the separator to prevent the separator from fluttering beforethe separator is cut by the cutting member.

BRIEF DESCRIPTION OF THE DRAWINGS

The above objective and advantages of the present invention will becomemore apparent by describing in detail preferred embodiments thereof withreference to the attached drawings in which:

FIG. 1 is a schematic perspective view illustrating a packing apparatusfor an automated manufacturing system of a lithium secondary batteryaccording to a preferred embodiment of the present invention;

FIG. 2 is a front view illustrating an example in which the separatorstrip is folded in the shape of “Z” by the lamination unit shown in FIG.1;

FIGS. 3A and 3B are front and plan views of a packing apparatus shown inFIG. 1;

FIGS. 4A and 4B are expanded front and plan views of a base memberportion shown in FIG. 3;

FIGS. 5A and 5B are front and right side views of a stopper member and afolder member shown in FIG. 3, respectively;

FIGS. 6A and 6B are front and right side views of a clamp member portionshown in FIG. 3;

FIGS. 7A and 7B are front and right side views of a cutting memberportion shown in FIG. 3;

FIGS. 8A and 8B are front and right side views of a tape supplyingmember portion shown in FIG. 3; and

FIGS. 9A, 9B, and 9C are views of a holder member portion shown in FIG.3.

DETAILED DESCRIPTION OF THE INVENTION

Now, a packing apparatus for an automated manufacturing system of alithium secondary battery according to a preferred embodiment of thepresent invention will be described in detail with reference to theattached drawings.

Referring to FIG. 1, a packing apparatus 350 according to the presentinvention is intended to fold the separator 311 supplied through theleading end of the transporting unit (not shown), after the separator311 is laminated with the positive and negative electrode plates 102 and104 by the lamination unit (not shown), so that the section of theseparator 311 can have the shape of “Z”, that is fold/fold fashion, asshown in FIG. 2, and to tape the folded separator 311 with a tape.

FIGS. 3A and 3B are front and plan views of the packing apparatus shownin FIG. 1.

Referring to FIG. 1 and FIGS. 3A and 3B, the packing apparatus 350comprises a frame 301, a base member 210 to which one batch of theseparator 311 both surfaces of which have been laminated with aplurality of positive and negative electrode plates 102 and 104 in apredetermined pattern is supplied, and in which the one batch of theseparator 311 is received, a stopper member 220 installed at the frame301 to be raised and lowered so that the separator 311 received in thebase member 210 can be prevented from being separated from the receivingrack 212, a folder member 230 continuously reciprocating to fold theseparator 311 supplied to a receiving space 214 formed by the receivingrack 212 and the stopper member 220 so that the section of the separator311 can have the shape of “Z”, a cutting/taping member 240 for movingthe separator 311 folded in the shape of “Z” to a predetermined tapingposition, for cutting a non-electrode-plate area of the separator 311 towhich any electrode plate is not attached, and for taping the cutseparator 311.

The frame 301 may be divided into a lower frame at which a plurality ofsupporting pillars 309 for supporting the packing apparatus 350 apartfrom the floor are installed, and an upper frame on which components ofthe apparatus 350 are seated. Various driving motors, a vacuum system,an air system, an electronic system, an adhesive supplying system, andthe like are provided at the lower frame. It is preferable that theupper surface of the upper frame is arranged to be in an accuratelyhorizontal state.

FIGS. 4A and 4B are expanded front and plan views of the portion of thebase member of the packing apparatus.

Referring to FIGS. 4A and 4B, the base member 210 comprises a receivingrack 212 which has a planar shape and is installed at the base plate 216installed at the frame 301, a guiding jaw 218 projected from the baseplate 216 for guiding the supplied separator 311 toward the receivingrack 212, and a pair of recessed portions 211 recessed into both sidesof the receiving rack 212. It is preferable that the upper surface ofthe guiding jaw 218 is disposed to be parallel to the travel path 313and is specially surface-treated. The recessed portion 211 is a spaceinto which a finger member 245 (FIGS. 6A and 6B) of the cutting/tapingmember 240 is inserted.

In addition, the base member 210 further comprises a biasing member 213for biasing the separator 311 toward the direction opposite to theseparator supplied direction, that is, toward the stopper member 220 sothat the separator 311 supplied to the receiving rack 212 can be easilyfolded to be almost the shape of “Z”. It is preferable that the biasingmember 213 comprises an air nozzle 215 capable of pushing the separator311 fluttering due to air blowing force toward the stopper member 220.

FIGS. 5A and 5B are front and right side views of the stopper member andthe folder member shown in FIG. 1.

Referring to FIGS. 5A and 5B, the stopper member 220 is installed to becapable of being moved linearly back and forth with respect to the frame301 by a stopper moving member 222 which is installed at the frame 301and is controlled by the control unit so that the stopper member 220 canblock selectively a side of the base member 210 to form the receivingspace 214 and prevent the separator 311 supplied to the receiving rack212 from being separated from the receiving rack 212. It is preferablethat the stopper member 220 has two stopper forks 224 at its one end,and a vacant space is formed between the two stopper forks 224.

The folder member 230 is intended to continuously press and fold theseparator 311 supplied to the receiving space 214 and biased toward thestopper member 220 so that the sections of the separator 311 at bothside portions of the positive electrode plates 102 and the negativeelectrode plates 104 can have the shape of “z”, and to cause thepositive electrode plates 102 and the negative electrode plates 104alternate with each other. The folder member 230 comprises a folderplate 232 disposed to be raised or lowered at a position correspondingto the receiving space 214, and a folder cylinder 234 which is installedat the stopper member 220 and controlled by the control unit. Therefore,during packing of a batch of the separator 311, while the stopper member220 moves back and forth once, the folder plate 232 moves back and forthas many times as the number of electrode plates required for a battery,that is, the number of the positive electrode plates and the negativeelectrode plates which alternate with each other.

Referring to FIGS. 6A and 6B, the cutting/taping member 240 comprises apair of clamp members 242 which approach both sides of the base member210, clamp both sides of a piece of separator which is folded in theshape of “z”, and are moved horizontally to a taping position, a cuttingmember 250 (FIGS. 7A and 7B) installed at the frame 301 to be movablefor cutting the separator 311 from above the base member 210 after thepiece of separator 311 is moved by the clamp members 242, a tapesupplying member 270 (FIG. 1 and FIG. 3) installed at the frame 301 soas to attach one end of a tape 262 to a piece of separator 311 after atape roller 264 around which the tape 262 is wound is moved to thetaping position through a tape travel path, clamp rotating members 280(FIGS. 6A and 6B) installed at the frame 301 for rotating the clampmembers 242 predetermined times so that the piece of separator can betaped while the piece of separator to which one end of the tape 262 isattached is rotated at both ends thereof, a tape cutting member 290(FIG. 3A) installed at the frame 301 to be movable for cutting the looseend portion of the tape 262 extended from the packed piece of separator311 which has been rotated by the clamp rotating members 280 and hasbeen packed with the tape 262, and a holder member 244 installed at theframe 301 to be raised and lowered so that the holder member 244 canapproach the tape supplying member 270 and contact the lower surface ofthe separator 311 to prevent the separator 311 from fluttering beforethe separator 311 is cut by the cutting member 250.

Referring to FIGS. 6A and 6B, the pair of clamp members 242 areinstalled to be symmetrical with respect to the travel path of theseparator 311 and to be parallel to the frame 301. Each clamp member 242comprises a movable block 241 which is moved back and forth between thebase member 210 and the taping position along an LM guide 246 and guiderails 248 which are parallel to the travel path of the separator 311,and a pair of finger members 245 installed at the movable block 241 soas to clamp the piece of separator 311 while being positioned at therecessed portion 211 and being operated by an air cylinder 243.

As shown in FIGS. 7A and 8B, the cutting member 250 is intended to cutthe leading end of a non-attached area of the piece of separator 311moved to the taping position by the clamp members 242, and comprises aheating cutter 258 which is provided with a heating wire 252. Theheating cutter 258 is installed at one end of a cylinder 254 to bedisposed over the travel path 313 so that the heating cutter 258 can beselectively moved toward the base member 210 by the cylinder 254 tocontact the separator 311, and the heating wire 252 heated to apredetermined temperature can cut the separator 311. The cylinder 254 issupported by a bracket 252 which is installed at the frame 301.

Referring to FIG. 1 and FIGS. 8A and 8B, the tape supplying member 270comprises a tape roller 264 and a plurality of tape guiding rollers 266which are installed at the frame 301, and a pair of tape attachingrollers 272 which are installed at one end of a cylinder 268 installedat the frame 301 to be raised or lowered by the cylinder 268 and arepositioned on the travel path of the tape 262 so that one end of thetape 262 can selectively contact the upper surface of the separator 311.

As shown in FIGS. 9A and 9B, the holder member 244 is disposed tocorrespond to the tape attaching rollers 272. The holder member 242 isintended to prevent a non-attached area of the separator 311 fromfluttering since the separator 311 is cut before a piece of separator311 is taped, and, therefore, the fluttering occurs. To this end, theholder member 244 comprises a bracket 274 installed at the frame 301,and a holding roller 278 installed so as to be selectively raised andlowered by a cylinder 276 installed at a bracket 274 until the holdingroller 278 contact the lower surface of the separator 311.

As shown in FIGS. 6A and 6B, each of the clamp rotating members 280comprises a stepping motor 282 installed at the movable block 241 sothat the axis of rotation of the stepping motor 282 can be coaxial withthat of the finger members 245, and, therefore, the clamp rotatingmember 280 can rotate the finger members 245 with the rotational forcethereof.

As shown in FIGS. 9A and 9C, the tape cutting member 290 is installed atthe frame 301 to be close to the holder member 244 so that the tapecutting member 290 can be rotated by the clamp rotating member 280(FIGS. 6A and 6B), and cut the loose end portion of the tape 262 (FIG.3A) extended from the packed piece of separator 311. The tape cuttingmember 290 comprises a bracket 292 installed at the frame 301, and acutting body 296 having a cutting wire 295 for heating and cutting thetape 262, which is raised and lowered by a cylinder 294 which isinstalled at the bracket 292 and is operated below the travel path bythe control unit.

The operation of the packing apparatus for an automated manufacturingsystem of a lithium secondary battery configured as above according to apreferred embodiment of the present invention will be described.

First, the power of the packing apparatus 350 is turned on, and datarequired for the control unit is set. Then, the separator 311 bothsurfaces of which the positive and negative electrode plates 102 and 104have been attached to in the predetermined pattern is prepared to besupplied via the travel path 313. In addition, the stopper member 220 islowered to block both sides of the base member 210 and to form thereceiving space 214 above the receiving rack 212.

Subsequently, when a start button of the control unit is pressed, theseparator 311 which was supplied by the transporting unit begins to besupplied to the receiving rack 212 of the base member 210 guided by theguiding jaw 218. In this step, the separator 311 is biased toward thestopper member 230 by the air blowing force generated by the air nozzle215 of the biasing member 213.

In this state, the folder plate 232 of the folder member 230continuously presses the separator 311 supplied to the receiving space214 and biased by a predetermined times, and folds the separator 311 sothat the sections of both sides of the separator 311 can have the shapeof “Z”, and the positive electrode plates 102 and the negative electrodeplates 104 can alternate with each other. Then, the stopper member 220is raised in a state that the folder plate 232 presses a piece ofseparator 311 against the receiving rack 212. Subsequently, the clampmembers 242 of the cutting/taping member 240 are caused to approach theboth sides of the base member 210, and clamp both sides of the piece ofseparator 311 folded in the shape of “Z”. Together with the clampingoperation, the folder plate 232 is raised.

Thereafter, the clamp members 242 are operated to move the piece ofseparator 311 horizontally to a taping position. Subsequently, the tapesupplying member 270 is operated to cause the leading end of the tape262 to adhere to the upper surface of the piece of separator 311positioned at the taping position. At the same time, the holder member244 is raised to cause the holding roller 278 to contact the lowersurface of the separator 311. Therefore, since the tape attachingrollers 272 and the holding roller 278 hold the separator 311, theseparator 311 does not flutter.

Subsequently, the cutting member 250 is lowered to cut the leading endof a non-attached area of the piece of separator 311. Then, the heatingcutter 258 heated to a predetermined temperature cuts the separator 311.

Thereafter, while the piece of separator 311 to which the leading end ofthe tape 262 is adhered is rotated at both ends thereof, the clamprotating members 280 are operated to tape the piece of separator 311.Then, the finger members 245 are rotated by the stepping motors 282,and, at the same time, the tape 262 supplied from the tape supplyingmember 270 is naturally wound around the piece of separator 311 to tapethe piece of separator 311.

Subsequently, the tape cutting member 290 is operated to cut the looseend of the tape 262 extended from the taped piece of separator 311.Then, the cutting wire 295 is moved to cut the tape 262 by using heat,and the packing operation is finally completed.

As described above, the packing apparatus for an automated manufacturingsystem of a lithium secondary battery according to the present inventionhas the following advantages.

First, the overall efficiency of production thereof can be enhanced dueto the employment of the automated manufacturing system, and a rate ofdefective secondary batteries can be lowered.

Second, since the separator both surfaces of which positive electrodeplates and negative electrode plates are attached to, respectively, canbe folded by serialized operations of the receiving rack, the stoppermember, and the pressing plate so that both side sections of the foldedseparator can have the shape of “Z”, productivity of secondary batteriescan be enhanced markedly.

Third, since folded pieces of separator can be continuously moved, andtaped by automated robot equipments, productivity of secondary batteriesand efficiency of manufacturing processes can be enhanced.

While this invention has been particularly shown and described withreference to preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the spirit and scope of theinvention as defined by the appended claims.

1. A packing apparatus for an automated manufacturing system of asecondary lithium battery comprising: a frame; a base member which isinstalled at the frame, and is provided with a receiving rack forreceiving a batch of separator both surfaces of which are laminated atpredetermined intervals with positive electrode plates and negativeelectrode plates; a stopper member installed at the frame to be linearlymovable so as to selectively approach one end of the base member forpreventing the separator being supplied to the base member from beingseparated from the receiving rack; a folder member having a folder plateinstalled at the frame and a folder cylinder for verticallyreciprocating the folder plate, the folder plate being linearly movablewith respect to the receiving rack so that the folder can press theseparator supplied to a receiving space formed by the receiving rack andthe stopper member for predetermined duration, and fold the separator sothat both side sections of the folded separator can have the shape of“Z”, and the positive electrode plates and the negative electrode platescan alternate with each other; and a cutting/taping member for movingthe separator folded in the shape of “Z” to a predetermined area,cutting the separator at a non-electrode area to which no electrode isattached, and the binding the circumference of the separator folded inthe shape of a “Z” with a tape; wherein, while one batch of separator iscompletely folded in the shape of a “Z” by the folder member, thestopper member is positioned adjacent to one end of the base member forpreventing the separator from being separated from the receiving rack.2. The packing apparatus for an automated manufacturing system of asecondary lithium battery claimed as in claim 1, wherein the base membercomprises: a guiding jaw projected from a base plate to guide theseparator supplied thereto; and a pair of recessed portions recessedinto both sides of the receiving rack.
 3. The packing apparatus for anautomated manufacturing system of a secondary lithium battery claimed asin claim 1, wherein the base member further comprises a biasing memberinstalled at the frame for biasing the separator toward the stoppermember so that the separator supplied to the receiving rack can beeasily folded in the shape of “Z”.
 4. The packing apparatus for anautomated manufacturing system of a secondary lithium battery claimed asin claim 1, wherein the stopper member has a stopper fork for blockingboth sides of the base member, and is linearly moved by a stopper movingmember.
 5. The packing apparatus for an automated manufacturing systemof a secondary lithium battery claimed as in claim 1, wherein thecutting/taping member comprises: a pair of clamp members for approachboth sides of the base member, clamping both sides of a piece ofseparator folded in the shape of “Z”, and moving the piece of separatorhorizontally to a taping position; a cutting member installed at theframe to be movable for cutting the separator at the leading end of thebase member after the separator has been moved by the clamp member; atape supplying member installed at the frame to attach one end of tapeto the piece of separator after a tape roller around which the tape iswound is moved along a tape travel path; clamp rotating membersinstalled at the frame for rotating the clamp members predeterminedtimes so that the piece of separator can be taped while the piece ofseparator to which one end of the tape is attached is rotated at bothends thereof; and a tape cutting member installed at the tape supplyingmember to be movable for cutting the loose end portion of the tapeextended from the packed piece of separator which has been rotated bythe clamp rotating members and has been packed with the tape.
 6. Thepacking apparatus for an automated manufacturing system of a secondarylithium battery claimed as in claim 5, wherein the cutting/taping memberfurther comprises a holder member installed at the frame to be raisedand lowered so that the holder member can approach the tape supplyingmember and contact one surface of the separator to prevent the separatorfrom fluttering before the separator is cut by the cutting member.